TOX FinePress ZFS User manual

Original operating instructions
TOX® FinePress
ZFS / ZFL / ZFW
TOX® PRESSOTECHNIK GmbH & Co. KG, Riedstrasse 4, 88250 Weingarten / Germany
www.tox.com
Edition:11/20/2023, Version: 6

Table of contents
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 2
Table of contents
1 Important information
1.1 Legal note ....................................................................................................6
1.2 Exclusion of liability......................................................................................6
1.3 Conformity ...................................................................................................6
1.4 Validity of the document ..............................................................................7
1.4.1 Content and target group.............................................................................7
1.4.2 Other applicable documents ........................................................................7
1.5 Gender note.................................................................................................7
1.6 Displays in the document.............................................................................8
1.6.1 Display of warnings......................................................................................8
1.6.2 Display of general notes ..............................................................................8
1.6.3 Highlighting of texts and images..................................................................9
1.7 Contact and source of supply ....................................................................10
2 Safety
2.1 Basic safety requirements .........................................................................11
2.2 Organizational measures...........................................................................12
2.2.1 Safety requirements for the operating company........................................12
2.2.2 Selection and qualifications of personnel ..................................................13
2.3 Fundamental hazard potential ...................................................................14
2.3.1 Electrical hazards ......................................................................................14
2.3.2 Thermal hazards........................................................................................14
2.3.3 Pneumatic hazards ....................................................................................15
2.3.4 Contusions.................................................................................................15
2.3.5 Hydraulic hazards ......................................................................................15
2.3.6 Electromagnetic hazards ...........................................................................16
2.3.7 Laser..........................................................................................................16
2.3.8 Hazardous substances ..............................................................................16
2.3.9 Noise..........................................................................................................17
2.4 Safety symbols ..........................................................................................18

Table of contents
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 3
3 About this product
3.1 Intended use ..............................................................................................19
3.1.1 Safe and correct operation ........................................................................19
3.1.2 Foreseeable misuse ..................................................................................20
3.1.3 Substances harmful to the wetting properties of lacquers (LABS) ............20
3.2 Product identification .................................................................................20
3.2.1 Type plate ..................................................................................................20
3.3 Product overview and function description ................................................21
4 Technical data
4.1 Type sheet and data sheet ........................................................................22
5 Transport and storage
5.1 Safety during transport ..............................................................................23
5.2 Storage when not in use ............................................................................24
5.3 Transport by lifting device..........................................................................25
5.4 Dispatch for repair .....................................................................................26
6 Installation
6.1 Safety during installation............................................................................27
6.2 Requirements for installation .....................................................................29
6.2.1 Set-up location...........................................................................................29
6.3 Installing accessories.................................................................................30
6.3.1 Installing process monitoring (option) ........................................................30
6.3.2 Installing the ergonomic handle (optional) .................................................31
6.3.3 Installing the stroke counter (optional).......................................................32
6.3.4 Installing the force sensor (optional)..........................................................34
6.3.5 Install the return stroke lock (option)..........................................................36
6.3.6 Installing the slide table (optional) .............................................................38
6.3.7 Installing travel sensor (option)..................................................................39
6.3.8 Installing the tool holding fixture (optional) ................................................40

Table of contents
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 4
7 Commissioning
7.1 Safety during the commissioning...............................................................41
7.1.1 Safety device .............................................................................................41
7.2 Requirements for the commissioning ........................................................42
8 Operation
8.1 Safety in operation.....................................................................................43
8.2 Requirements for operation .......................................................................43
8.3 Process monitoring ....................................................................................43
8.4 Setting the open height of the press head.................................................44
8.5 Fine adjustment of working stroke (option)................................................46
8.6 Setting working depth ................................................................................47
8.7 Resetting the stroke counter (optional)......................................................47
8.8 Adjusting the return stroke lock (optional) .................................................48
8.9 Setting the return stroke ............................................................................51
8.10 Setting the travel sensor (option)...............................................................52
9 Troubleshooting
9.1 Safety during troubleshooting ....................................................................53
9.2 Detecting faults ..........................................................................................54
Maintenance table
10 Maintenance
10.1 General information ...................................................................................56
10.2 Safety during maintenance ........................................................................57
10.3 Requirements for maintenance..................................................................57
10.3.1 Set system to maintenance position ..........................................................57
10.4 TOX® FinePress maintaining .....................................................................58
10.4.1 TOX® FinePress inspecting .......................................................................58
10.4.2 Inspecting the fastening of the press head ................................................59
10.4.3 Inspecting and cleaning movable parts and guides...................................60

Table of contents
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 5
11 Repairs
11.1 Safety during repairs..................................................................................61
12 Disassembly and Disposal
12.1 Safety during disassembly and disposal....................................................62
12.2 Decommissioning ......................................................................................62
12.3 Shutdown...................................................................................................63
12.4 Disassembling ...........................................................................................64
12.5 Disposal .....................................................................................................64
13 Appendices
13.1 Declaration of conformity ...........................................................................65
Index

Important information
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 6
1 Important information
1.1 Legal note
All rights reserved.
Operating instructions, manuals, technical descriptions and software published
by TOX®PRESSOTECHNIK GmbH & Co. KG ("TOX®PRESSOTECHNIK") are
copyright and must not be reproduced, distributed and/or otherwise processed
or edited (e.g. by copying, microfilming, translation, transmission in any elec-
tronic medium or machine-readable form). Any use - including of extracts - con-
trary to this condition is prohibited without approval in writing by TOX®PRES-
SOTECHNIK and may be subject to criminal and civil legal sanctions.
If this manual refers to goods and/or services of third parties, this is for example
only or is a recommendation by TOX®PRESSOTECHNIK. TOX®PRES-
SOTECHNIK does not accept any liability or warranty/guarantee with reference
to the selection, specifications and/or usability of these goods and services. The
use and/or representation of trademarked brands that do not belong to
TOX®PRESSOTECHNIK are for information only; all rights remain the property
of the owner of the trademarked brand.
Operating instructions, manuals, technical descriptions and software are origi-
nally compiled in German.
1.2 Exclusion of liability
TOX®PRESSOTECHNIK has checked the contents of this publication to ensure
that it conforms to the technical properties and specifications of the products or
plant and the description of the software. However, discrepancies may still be
present, so we cannot guarantee complete accuracy. The supplier documenta-
tion included with the system documentation is an exception.
However, the information in this publication is checked regularly and any re-
quired corrections are included in subsequent editions. We are grateful for any
corrections and suggestions for improvement. TOX®PRESSOTECHNIK re-
serves the right to revise the technical specifications of the products or plant
and/or the software or documentation without prior notice.
1.3 Conformity
The product is compliant with EU guidelines.
See separate Declaration of conformity or installation declaration.

Important information
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 7
1.4 Validity of the document
1.4.1 Content and target group
This manual contains information and instructions for the safe operation and
safe maintenance or servicing of the product.
All information in this manual is up to date at the time of print. TOX®PRES-
SOTECHNIK reserves the right to make technical changes that improve the
system or increase the standard of safety.
The information is intended for the operating company as well as operating
and service personnel.
1.4.2 Other applicable documents
In addition to the available manual, further documents can be supplied. These
documents must also be complied with. Other applicable documents can be, for
example:
additional operating manuals (e.g. of components or of a whole system)
Supplier documentation
Instructions, such as software manual, etc.
Technical data sheets
Safety data sheets
Data sheets
Schematics
1.5 Gender note
In order to enhance readability, references to persons that also relate to all
sexes are normally only stated in the usual form in German or in the corre-
sponding translated language in this manual, thus e.g. "operator" (singular) for
male or female, or "operators" (plural) for male or female". This should in no
way convey any gender discrimination or any violation of the principle of equal-
ity, however.

Important information
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 8
1.6 Displays in the document
1.6.1 Display of warnings
Warning signs indicate potential dangers and describe protective measures.
Warning signs precede the instructions for which they are applicable.
Warning signs concerning personal injuries
DANGER
Identifies an immediate danger!
Death or severe injuries will occur if appropriate safety measures are not taken.
èMeasures for remedial action and protection.
WARNING
Identifies a potentially dangerous situation!
Death or serious injury may occur if appropriate safety measures are not taken.
èMeasures for remedial action and protection.
CAUTION
Identifies a potentially dangerous situation!
Injury may occur if appropriate safety measures are not taken.
èMeasures for remedial action and protection.
Warning signs indicating potential damage
NOTE
Identifies a potentially dangerous situation!
Property damage may occur if appropriate safety measures are not taken.
èMeasures for remedial action and protection.
1.6.2 Display of general notes
General notes show information on the product or the described action steps.

Important information
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 9
Identifies important information and tips for users.
1.6.3 Highlighting of texts and images
The highlighting of texts facilitates orientation in the document.
üIdentifies prerequisites that must be followed.
1. Action step 1
2. Action step 2: identifies an action step in an operating sequence that must
be followed to ensure trouble-free operation.
wIdentifies the result of an action.
uIdentifies the result of a complete action.
èIdentifies a single action step or several action steps that are not in an oper-
ating sequence.
The highlighting of operating elements and software objects in texts facilitates
distinction and orientation.
<In square brackets> identifies operating elements, such as buttons, levers
and (valves) stopcocks.
''with quotation marks'' identifies software display panels, such as windows,
messages, display panels and values.
In bold identifies software buttons, such as buttons, sliders, checkboxes
and menus.
In bold identifies input fields for entering text and/or numerical values.

Important information
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 10
1.7 Contact and source of supply
Only use original spare parts or spare parts approved by TOX®PRESSOTECH-
NIK.
TOX®PRESSOTECHNIK GmbH & Co. KG
Riedstraße 4
88250 Weingarten / Germany
Tel. [phone]
E-Mail: [email protected]
For additional information and forms see
www.tox.com

Safety
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 11
2 Safety
2.1 Basic safety requirements
The product is state of the art. However, operation of the product may involve
danger to life and limb for the user or third parties or damage to the plant and
other property.
For this reason the following basic safety requirements will apply:
Read the operating manual and observe all safety requirements and warn-
ings.
Operate the product only as specified and only if it is in perfect technical
condition.
Remedy any faults in the product or the plant immediately.

Safety
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 12
2.2 Organizational measures
2.2.1 Safety requirements for the operating company
The operating company is responsible for compliance with the following safety
requirements:
The operating manual must always be kept available at the operation site of
the product. Ensure that the information is always complete and in legible
form.
In addition to the operating manual, the generally valid legal and other bind-
ing rules and regulations must be provided for the following content and all
personnel must be trained accordingly:
– Work safety
– Accident prevention
– Working with hazardous substances
– First aid
– Environmental protection
– Traffic safety
– Hygiene
The requirements and contents of the operating manual must be supple-
mented by existing national regulations (e.g. for prevention of accidents and
for environmental protection).
Instructions for special operating features (e.g. work organization, work pro-
cesses, appointed personnel) and supervisory and reporting obligations
must be added to the operating manual.
Take action to ensure safe operation and make sure that the product is
maintained in a functional condition.
Only allow authorized persons access to the product.
Ensure that all personnel work with awareness of safety and potential dan-
gers with reference to the information in the operating manual.
Provide personal protective equipment.
Maintain all safety and information on dangers regarding the product com-
plete and in legible condition and replace as required.
Do not make any changes, carry out attachments or conversions to the
product without the written approval of TOX®PRESSOTECHNIK. Action
contrary to the above will not be covered by the warranty or the operating
approval.
Make sure that the annual safety inspections are carried out and docu-
mented by an expert.

Safety
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 13
2.2.2 Selection and qualifications of personnel
The following safety requirements are applicable for the selection and qualifica-
tions of personnel:
Only appoint persons to work on the plant who have read and understood
the operating manual, and in particular, the safety instructions before start-
ing work. This is particularly important for persons who only work on the
plant occasionally, e.g. for maintenance work.
Only allow persons appointed and authorized for this work access to the
plant.
Only appoint reliable and trained or instructed personnel.
Only appoint persons to work in the danger zone of the plant who can per-
ceive and understand visual and acoustic indications of danger (e.g. visual
and acoustic signals).
Ensure that assembly and installation work and the initial commissioning
are performed exclusively by qualified personnel who have been trained
and authorized by TOX®PRESSOTECHNIK.
Maintenance and repairs must be performed by qualified and trained per-
sonnel only.
Ensure that personnel who are being trained, instructed or are in an ap-
prenticeship can only work on the plant under the supervision of an experi-
enced person.
Have work on electrical equipment performed only by electricians or trained
persons under the direction and supervision of an electrician in accordance
with the electrotechnical regulations.

Safety
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 14
2.3 Fundamental hazard potential
Fundamental hazard potentials exist. The specified examples draw attention to
known hazardous situations, but are not complete and do not in any way pro-
vide safety and risk awareness action in all situations.
2.3.1 Electrical hazards
Attention should be paid to electrical hazards particularly inside the components
in the area of all assemblies of the control system and motors of the installation.
The following basically applies:
Have work on electrical equipment performed only by electricians or trained
persons under the direction and supervision of an electrician in accordance
with the electrotechnical regulations.
Always keep the control box and/or terminal box closed.
Before commencing work on electrical equipment, switch off the main
switch of the system and secure it against being switched back on inadver-
tently.
Pay attention to the dissipation of residual energy from the control system
of the servomotors.
Make sure that the components are disconnected from the power supply
when carrying out the work.
2.3.2 Thermal hazards
During operation piece parts may become hot and cause burns when touched.
Hazardous positions are generally marked with a symbol.
See Safety symbols, Page 18
Wear individual protective equipment.
Before starting work, make sure that surfaces have cooled down suffi-
ciently.

Safety
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 15
2.3.3 Pneumatic hazards
Attention must be paid to pneumatic hazards particularly on the pneumatic sup-
ply lines and connection points.
The following basically applies:
Allow work to be carried out on pneumatic equipment by authorized service
personnel only.
Wear individual protective equipment.
Do not exceed the permissible pressure.
First switch on compressed air when all hose connections have been estab-
lished and secured.
Do not uncouple any hoses under pressure.
If hoses slip off, switch off the compressed air supply immediately.
2.3.4 Contusions
Contusions and hand injuries can occur in the radius of action of the product.
The following applies generally:
Make sure that that no persons are located in the danger area during oper-
ation.
During necessary work in the danger area (e.g. maintenance, cleaning), se-
cure the system against unexpected, accidental and unauthorized activa-
tion.
Make sure that parts or tools cannot fall down or descend as a result of
stored energy. Use appropriate fuses.
2.3.5 Hydraulic hazards
Attention must be paid to hydraulic hazards particularly on the supply lines, con-
nection points and vent points.
The following applies generally:
Allow work to be carried out on hydraulic equipment by authorized service
personnel only.
Wear individual protective equipment.
Do not exceed the permissible pressure.
Do not remove any hoses under pressure.
Never vent hydraulic components under pressure.

Safety
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 16
2.3.6 Electromagnetic hazards
Electromagnetic hazards are to be taken into account in the area of electromag-
netically vibrating or oscillating components.
Regular work on and with electromagnetically vibrating or oscillating compo-
nents can cause disorders in the blood flow of the fingers as well as neurologi-
cal and motoric dysfunctions.
The following applies generally:
Wear protective anti-vibration gloves when performing necessary work!
Electromagnetic fields can have an indirect effect on heart pacemakers and
other implants. Adhere to safety distances.
2.3.7 Laser
Depending on the model and features, lasers can be installed for the purpose of
recognition. There is a danger of looking into the laser in some situations. If this
is not avoided, eye injuries may result.
The following applies generally:
Do not look into the direct or the reflected beam.
If the laser beam hits the eye, deliberately close the eyes and move the
head immediately out of the beam.
When using the laser, no optical instruments are to be used for viewing the
source of the beam, since this can lead to exceeding the exposure limit val-
ues.
Manipulation (modification) of the laser equipment is inadmissible.
2.3.8 Hazardous substances
The following safety requirements apply when handling chemical substances:
Observe the applicable safety regulations on handling chemical substances
and the information on the manufacturer's safety data sheets of hazardous
substances.
Wear individual protective equipment.
In the event of eye or skin contact, rinse the affected area, change contami-
nated clothing and visit a doctor if necessary. Provide appropriate equip-
ment (eye wash bottle, washbasin) near the workplace.
Groundwater hazardous substances must not get into the ground or
sewage system. Collect groundwater hazardous substances and dispose of
them properly.

Safety
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 17
2.3.9 Noise
Depending on the equipment, an increase in the noise level can arise in the
sphere of the product.
Keep the duration of the exposure at a minimum.
Wear individual protective equipment.

Safety
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 18
2.4 Safety symbols
Safety symbols are important components of the safety concept and help to
prevent accidents. The safety symbols provide information about potential haz-
ards that could cause serious injuries.
The following safety symbols can be attached on the product:
Symbol Hazard Notes
Warning of suspended load Do not stay in the danger zone of the
suspended load.
Identifies fork-lift truck brackets.
Identifies attachment point.
Warning of hot surfaces In the area of motors, drives and fans.
Warning of electrical voltage In the area of the entire control box.
Warning of crushing Risk of crushing in the working area.
Tab.1 Safety symbols

About this product
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 19
3 About this product
3.1 Intended use
The machine in conjunction with the designated tool is used for
Installing, press fitting
Punching, pressing (of function elements)
Riveting, crimping, flaring
Punching, piercing
Embossing, marking
Tensioning, clamping, crimping
Pressing, compressing
Clinching, joining
of sheet metal or mechanical modules.
3.1.1 Safe and correct operation
Intended use includes the following conduct:
Only operate with the components for which it is specified.
Follow all instructions in this operating manual.
Comply with the specified maintenance intervals and perform maintenance
work correctly.
Operate in compliance with the conditions of the technical data.
Operation with fully assembled and functional safety devices.
Activities may only be carried out by persons who are qualified or autho-
rized for this purpose.
Any other use or application beyond this does not come under the scope of in-
tended use.

About this product
TOX_Manual_FinePress_ZFS-ZFL-ZFW_en 20
3.1.2 Foreseeable misuse
Use contrary to intended use includes the following foreseeable misuse:
Operation under conditions that deviate from the technical data.
Operation without fully assembled and functional connections.
Operation without fully assembled and functional safety devices.
Modifications to the product without prior approval by TOX®PRES-
SOTECHNIK and the approving authority.
Incorrect parameterization.
Execution of activities by persons who are not qualified or authorized to do
so.
The operating company is exclusively responsible for all personal injury and
property damage resulting from non-intended use. Non-intended use will not be
covered by the warranty or the operating approval.
3.1.3 Substances harmful to the wetting properties of lacquers (LABS)
No substances containing silicone, are knowingly processed and used.
3.2 Product identification
3.2.1 Type plate
The details on the type plate ensure clear identification of components and the
specific operating parameters.
The type plate is attached permanently on the component.